Roof panel

ABSTRACT

A roof panel ( 1 ) for use in forming a low pitch or flat roof comprises a profiled inner liner or decking sheet ( 2 ), an outer waterproof membrane ( 3 ) and a body ( 4 ) of insulation between the inner liner ( 2 ) and outer membrane ( 3 ). The membrane liner sheet ( 3 ) has a backing such as a fleece or scrim to aid adhesion of the membrane ( 3 ) to the foam body. The membrane ( 3 ) comprises a side lap ( 5 ) extending sidewardly of at least some of the marginal edges of the body ( 4 ). The inner liner ( 2 ) comprises joint formations for forming a nested side lap joint between adjacent panels. The joint formations comprise a first joint formation ( 20 ) at one edge of the liner ( 2 ) and a second joint formation ( 21 ) on an opposite edge of the panel. The first and second joint formations ( 20, 21 ) of adjacent panels are adapted to interengage on assembly and are clinched together using a clinching tool ( 22 ) to form a clinched joint ( 25 ). The first joint formation ( 20 ) comprises a liner extension which is shaped to define a recess. There is an inturned liner leg and a return leg which define the liner recess therebetween. The second liner formation ( 21 ) comprises a liner extension which is shaped to define a projection which is engagable in the recess defined by the first liner extension ( 20 ). The liner projection is defined by an inturned liner leg which has a return lip to reinforce the projection. On assembly of adjacent panels on site, the liner formations ( 20 ), ( 21 ) are inter-engaged ed and clinched together. A foam filler ( 30 ) is provided at the joint.

INTRODUCTION

The invention relates to a roof panel for forming a low pitch or flat roof.

STATEMENTS OF INVENTION

According to the invention there is provided a roof panel for forming a low pitch or a flat roof, the roof panel comprising:

-   -   an inner liner;     -   an outer weatherproof membrane;     -   a body of insulating material between the inner liner and the         outer membrane;

wherein the inner liner comprises joint formations for forming a nested side lap joint between adjacent panels.

In one embodiment the joint formations are adapted for clinching.

In one case the joint formations comprise a first joint formation on one edge of the liner and a second joint formation on an opposite edge of the liner, the first liner formation of one panel being adapted for interengaging and for clinching with a second liner form of an adjacent panel.

The first liner formation may comprise a liner extension which is shaped to define a recess. The second liner formation may comprise a liner extension which is shaped to form a liner projection for locating in the liner recess of an adjacent panel.

The liner may comprise an inturned leg and a return leg which define the liner recess therebetween.

The liner may comprise an inturned leg which defines the liner projection. The liner projection may have a return lip to reinforce the projection.

In one embodiment the panel comprises a fastener for fastening the panel to a support such as a purlin. The fastener may be a self-coring fastener.

In one embodiment the panel comprises a filler for location in the nested side lap joint forming portions of the inner liner. The filler may be of insulation material.

In one embodiment the membrane comprises an integral side lap extending sidewardly of at least some of the marginal edges of the insulation, and the side lap being extendable over the joint between adjacent panels to form a sealed joint between adjacent panels on assembly.

The membrane may comprise a unitary sheet of membrane or film. The membrane may be substantially planar. The membrane may be of substantially uniform structure and thickness.

In one case the membrane is of a flexible plastics material. The membrane may be pre-attached to the insulation body except at a fixing region at one or more of the marginal edges. The side lap of the membrane may be extended to cover the fixing region on assembly.

In one case the body of insulation comprises an insulation foam. The insulation foam may be factory formed in situ between the inner liner and the outer layer.

In one embodiment the inner liner is of metal. The liner may be a profiled liner.

In one embodiment the liner comprises nestable partial profiles at the side marginal edges thereof.

The joint formations may be provided at the edge of the partial profiles.

In one embodiment the partial profiles are free of insulating material prior to assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more clearly understood from the following description thereof given by way of example only, in which:

FIG. 1 is a cross sectional view of a roof panel according to the invention;

FIG. 2 is a cross sectional view of a joint between two adjacent roof panels;

FIG. 3 is an enlarged cross sectional view of the joint detail;

FIG. 4 is a cross sectional view of a liner joint detail; and

FIG. 5 is a cross sectional view of a clinched linear joint.

DETAILED DESCRIPTION

Referring to the drawings there is illustrated a roof panel 1 according to the invention for use in forming a low pitch or flat roof.

The roof panel 1 comprises a profiled inner liner or decking sheet 2, an outer waterproof membrane 3 and a body 4 of insulation between the inner liner 2 and outer membrane 3.

The membrane liner sheet 3 has a backing such as a fleece or scrim to aid adhesion of the membrane 3 to the foam body. The membrane 3 may be of a suitable plastics material such as PVC, TPO and the like. The plastics membrane 3 is provided with a suitable backing such as a fleece or fabric.

The membrane 3 comprises a side lap 5 extending sidewardly of at least some of the marginal edges of the body 4. The side lap 5 which does not have a fleece or fabric backing is extended over a joint between adjacent panels to form a sealed joint between the adjacent panels on assembly.

The membrane 3 is manufactured of a unitary sheet of membrane or film. The side lap 5 is integral with the membrane 3 pre-bonded to the panel. The membrane 3 is of substantially uniform structure and thickness throughout and is substantially planar.

The inner liner 2 which may be of painted galvanised steel is formed with trapezoidal portions 9 for improved mechanical and insulation performance.

The insulation may be of any suitable foam material such as a polyurethane foam, a polyisocyanurate foam, or a phenolic foam.

The inner liner 2 comprises joint formations a the side marginal edges thereof for forming a nested side lap joint between adjacent panels. The joint formations comprise a first joint formation 20 at one edge of the liner 2 and a second joint formation 21 on an opposite edge of the liner. The first and second joint formations 20, 21 of adjacent panels are adapted to interengage on assembly as illustrated in FIG. 4 and are clinched together using a clinching tool 22 as illustrated in FIG. 5 to form a clinched joint 25.

The first joint formation 20 comprises a liner extension which is shaped to define a recess. There is an inturned liner leg 26 and a return leg 27 which define a liner recess therebetween.

The second liner formation 21 comprises a liner extension which is shaped to define a projection which is engagable in the recess defined by the first liner extension 20. The liner projection is defined by an inturned liner leg which has a return lip 28 to reinforce the projection.

Partial formations, in this case partial trapezoidal portions 7, 8 at the side marginal edges of the liner 2 extend laterally of the liner 2 and are free of insulating foam material when manufactured for nesting at the joint between adjacent panels. The joint formations 20, 21 are provided at the free edges of the partial trapezoidal portions 7, 8. On assembly, the partial trapezoidal portions 7, 8 of adjacent panels are overlapped and interengaged for enhanced structural strength. On assembly of adjacent panels on site, the liner formations 20, 21 are inter-engaged and clinched together. The clinched joint is then covered with an insulating foam filler 30 to provide insulation at the joint.

Self coring fasteners 35 are used to fix the panels to an underlying support 36 such as a purlin or the like.

The membrane 3 is applied to the panel 1 at the site where the panel is manufactured. The membrane is bonded to the panel such that an integral membrane side lap 5 extends sidewardly of at least some of the marginal edges of the panel. The membrane 3 may be bonded to the panel except at one or more of the marginal edges. The membrane 3 has a generally smooth finish on the weather (outer) side. On the backing side of the membrane which is in contact with the foam there may be a fleece backing to assist in ensuring a good bond between the membrane 3 and the foam 4. The overlap portion 5 does not have a fleece backing.

The membrane has a side lap 5 to which the outer layer is not bonded and this side lap may be un-fleeced (no fabric) in this region or the adhesive may be covered with a release tape or the like.

A composite panel is produced by laying down liquid foam reactants onto the liner layer 2. The trapezoidal portions 7, 8 are left free from foam. The liquid foam reactants may be poured onto the inner liner 2 and the outer layer 3 applied over the liquid foam reactants. The sandwich thus formed is heated in an oven and the liquid foam reactants expand to fill the space between the inner liner 2 and the outer membrane layer 3.

The panel thus formed is cut to a desired length.

In use, a roof is built up by laying a number of the panels side by side on support purlins. The joints between adjacent panels are sealed by extending the sidelaps 5 over the joints between adjacent panels and by then applying the side or end laps which may be heat sealed, hot air welded, solvent welded or adhesively bonded to the membrane of an adjacent panel. The overlapping portion of a side or end lap where provided is extended over the free fixing region of the panel and may be similarly sealed to the outer layer.

The panels are formed so that on assembly and interengagement a generally flat face to enable the membrane cover to be extended to completely cover the panel and joints between adjacent panels on assembly.

In use, when the panels are overlapped on site primary fixing is carried out using self coring fasteners which are applied from above and core down through the foam 4 and fasten the liner 2 to the supporting structure 36 below. Side-lap clinching of the nested joints is then performed, again from above. Finally, the factory cut foam inserts 30 are applied and the membrane 5 lap joint is welded.

The roof panels of the invention offer considerable advantages both in terms of mechanical performance and thermal efficiency.

As shown in the drawings the invention provides a low pitch or flat roof system for the installation and assembly of a waterproof sealed roof.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail. 

1-29. (canceled)
 30. A roof panel for forming a low pitch or a flat roof, the roof panel comprising: an inner liner; an outer weatherproof membrane; a body of insulating material between the inner liner and the outer membrane; wherein the inner liner comprises joint formations for forming a nested side lap joint between adjacent panels.
 31. The roof panel as claimed in claim 30 wherein the joint formations are adapted for clinching.
 32. The panel as claimed in claim 30 wherein the joint formations comprise a first joint formation on one edge of the liner and a second joint formation on an opposite edge of the liner, the first liner formation of one panel being adapted for interengaging and for clinching with a second liner form of an adjacent panel.
 33. The panel as claimed in claim 32 wherein the first liner formation comprises a liner extension which is shaped to define a recess.
 34. The panel as claimed in claim 33 wherein the liner comprises an inturned leg and a return leg which define the liner recess therebetween.
 35. The panel as claimed in claim 32 wherein the second liner formation comprises a liner extension which is shaped to form a liner projection for locating in the liner recess of an adjacent panel.
 36. The panel as claimed in claim 35 wherein the liner comprises an inturned leg which defines the liner projection.
 37. The panel as claimed in claim 36 wherein the liner projection has a return lip to reinforce the projection.
 38. The panel as claimed in claim 30 comprising a fastener for fastening the panel to a support such as a purlin.
 39. The panel as claimed in claim 38 wherein the fastener is a self-coring fastener.
 40. The panel as claimed in claim 30 comprising a filler for location in the nested side lap joint forming portions of the inner liner.
 41. The panel as claimed in claim 40 wherein the filler is of insulation material.
 42. The panel as claimed in claim 30 wherein the membrane comprises an integral side lap extending sidewardly of at least some of the marginal edges of the insulation, and the side lap being extendable over the joint between adjacent panels to form a sealed joint between adjacent panels on assembly.
 43. The panel as claimed in claim 30 wherein the membrane comprises a unitary sheet of membrane or film.
 44. The panel as claimed in claim 30 wherein the membrane is substantially planar.
 45. The panel as claimed in claim 30 wherein the membrane is of substantially uniform structure and thickness.
 46. The panel as claimed in claim 30 wherein the membrane is of a flexible plastics material.
 47. The panel as claimed in claim 30 wherein the membrane is attached to the insulation body except at a fixing region at one or more of the marginal edges.
 48. The panel as claimed in claim 47 wherein the side lap of the membrane is extended to cover the fixing region on assembly.
 49. The panel as claimed in claim 42 wherein the side lap extends for bonding to an adjacent panel on assembly.
 50. The panel as claimed in claim 49 wherein the side lap is bonded to an adjacent panel on assembly.
 51. The panel as claimed in claim 30 wherein the body of insulation comprises an insulation foam.
 52. The panel as claimed in claim 51 wherein the insulation foam is factory formed in situ between the inner liner and the outer layer.
 53. The panel as claimed in claim 30 wherein the inner liner is of metal.
 54. The panel as claimed in claim 30 wherein the liner is a profiled liner.
 55. The panel as claimed in claim 54 wherein the liner comprises nestable partial profiles at the side marginal edges thereof.
 56. The panel as claimed in claim 55 wherein the joint formations are provided at the edge of the partial profiles.
 57. The panel as claimed in claim 56 wherein the partial profiles are free of insulating material prior to assembly. 